U.S. patent application number 14/819397 was filed with the patent office on 2016-02-11 for solar panel installation systems and methods.
The applicant listed for this patent is Sunrun South LLC. Invention is credited to Greg McPheeters, Geno Viscuso.
Application Number | 20160043689 14/819397 |
Document ID | / |
Family ID | 55268194 |
Filed Date | 2016-02-11 |
United States Patent
Application |
20160043689 |
Kind Code |
A1 |
McPheeters; Greg ; et
al. |
February 11, 2016 |
SOLAR PANEL INSTALLATION SYSTEMS AND METHODS
Abstract
Solar panel installation systems are disclosed that reduce or
eliminate the need for large, costly rails for mounting solar
panels on an installation surface. The systems may include an array
of framed solar modules supported above an installation surface
using a number of height-adjustable base members. Adjacent solar
modules in the array may be coupled to one another at or near their
corners using module links that can structurally couple the frames
of the adjacent solar modules together.
Inventors: |
McPheeters; Greg; (Santa
Clara, CA) ; Viscuso; Geno; (Shingle Springs,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sunrun South LLC |
San Luis Obispo |
CA |
US |
|
|
Family ID: |
55268194 |
Appl. No.: |
14/819397 |
Filed: |
August 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62033311 |
Aug 5, 2014 |
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62075607 |
Nov 5, 2014 |
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62138065 |
Mar 25, 2015 |
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62187995 |
Jul 2, 2015 |
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Current U.S.
Class: |
248/231.31 ;
248/205.1; 248/287.1 |
Current CPC
Class: |
F24S 25/61 20180501;
H02S 30/10 20141201; Y02B 10/10 20130101; F24S 25/70 20180501; H02S
20/23 20141201; F24S 2025/6008 20180501; F16B 2/065 20130101; F16B
2/185 20130101; H02S 20/30 20141201; Y02E 10/50 20130101; F24S
2025/6003 20180501; Y02B 10/20 20130101; Y02E 10/47 20130101 |
International
Class: |
H02S 20/30 20060101
H02S020/30; H02S 30/10 20060101 H02S030/10 |
Claims
1. A solar panel installation system, comprising: a
height-adjustable base member couplable to an installation surface;
and a slidable attachment member coupled to the height-adjustable
base member, wherein the height-adjustable base member is
adjustable to vary the distance between the installation surface
and the slidable attachment member, and wherein the slidable
attachment member is slidably adjustable in one dimension relative
to the height-adjustable base member.
2. The solar panel installation system of claim 1, further
comprising: a solar module frame retention member coupled to the
slidable attachment member configured to retain a flange of a solar
module frame.
3. The solar panel installation system of claim 2, further
comprising the solar module frame retained in the solar module
frame retention member.
4. The solar panel installation system of claim 2, further
comprising: a second solar module frame retention member coupled to
the slidable attachment member; and a second solar module frame
comprising a flange, wherein the flange of the second solar module
frame is retained in the second solar module frame retention
member.
5. The solar panel installation system of claim 1, wherein the
height-adjustable base member comprises a flashing.
6. The solar panel installation system of claim 5, further
comprising: a fastener inserted through an aperture in the flashing
coupling the height-adjustable base member to the installation
surface.
7. The solar panel installation system of claim 5, wherein the
height-adjustable base member comprises: an L-foot base located
beneath the flashing; a fastener inserted through an aperture in
the L-foot base coupling the L-foot base to the installation
surface; and a clamping L-foot clamped to the L-foot base and the
flashing.
8. A height-adjustable base member, comprising: a flashing; a
vertical component coupled to the flashing; and a slidable
attachment member coupling portion coupled to the vertical
component.
9. The height-adjustable base member of claim 8, wherein the
vertical component comprises a hollow post configured to receive a
fastener that extends through the flashing to couple the
height-adjustable base member to an installation surface.
10. The height-adjustable base member of claim 9, wherein the
slidable attachment member comprises a support mechanism
comprising: a cylindrically-shaped hollow member slidably
receivable by the post; and a locking member for slidably receiving
and releasably coupling to a slidable attachment member.
11. The height-adjustable base member of claim 8, wherein the
vertical component comprises an L-foot having a vertical component
arranged substantially perpendicular to the installation surface
and a horizontal component arranged substantially parallel to the
installation surface.
12. The height-adjustable base member of claim 11, the L-foot
comprising: a longitudinal aperture for receiving a fastener; and
an arm engagement surface, wherein the slidable attachment coupling
portion comprises and L-shaped arm comprising: a vertical component
arranged substantially perpendicular to the installation surface
and a horizontal component arranged substantially parallel to the
installation surface; and an L-foot engagement surface oriented in
a plane parallel to the arm engagement surface, wherein the
fastener couples the L-foot engagement surface to the arm
engagement surface.
13. The height-adjustable base member of claim 12, wherein the arm
engagement surface and L-foot engagement surface comprise textured
surfaces configured to prevent movement of the arm relative to the
L-foot.
14. The height-adjustable base member of claim 11, wherein the
L-foot comprises an aperture for receiving a fastener configured to
couple the height-adjustable base member to the installation
surface.
15. The height-adjustable base member of claim 11, further
comprising an L-foot base, the L-foot base comprising: at least one
aperture configured to receive a fastener for coupling the L-foot
base to the installation surface, wherein L-foot base located
between the flashing and the installation surface.
16. The height-adjustable base member of claim 15, wherein the
L-foot comprises: a clamping wedge and a base-engagement leg
extending substantially perpendicularly away from the horizontal
component towards the installation surface, the clamping wedge
comprising a sloped surface; a base-coupling wedge comprising a
sloped surface complementary to the sloped surface of the clamping
wedge; and a fastener extending from base-coupling wedge through an
aperture in the horizontal portion, wherein tightening the fastener
causes the base-engagement leg and the base-coupling wedge to be
urged towards opposing sides of the L-foot base thereby coupling
the clamping L-foot the L-foot base.
17. The height-adjustable base member of claim 16, wherein the
L-foot base comprises keyed channels for engaging the base
engagement leg and the base-coupling wedge.
18. A slidable attachment member, comprising: a slidable portion
configured to slidably and releasably attach to a height-adjustable
base member; and at least one frame retention member for receiving
a flange of a solar module frame.
19. The slidable attachment member of claim 18, wherein the at
least one frame retention member is integrally formed with the
slidable portion.
20. The slidable attachment member of claim 18, wherein the at
least one frame retention member is removably coupled to a top
surface of the slidable attachment member situated opposite an
installation surface.
21. The slidable attachment member of claim 20, wherein the at
least one frame retention member retains the flange of the solar
module frame, wherein the solar module frame is located at an edge
of a solar module array.
22. The slidable attachment member of claim 20, wherein the at
least one frame retention member comprises: a first frame retention
member that retains a flange of a first solar module frame; and a
second frame retention member that retains a flange of a second
solar module frame, wherein the first and second solar module
frames are located at in interior location of a solar module array.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/033,311, entitled "Solar Panel
Installation Systems and Methods," filed Aug. 5, 2014, the
disclosure of which is incorporated by reference herein in its
entirety; U.S. Provisional Patent Application Ser. No. 62/075,607,
entitled "SOLAR PANEL INSTALLATION SYSTEMS AND METHODS," filed Nov.
5, 2014, the disclosure of which is incorporated by reference
herein in its entirety; U.S. Provisional Patent Application Ser.
No. 62/138,065, entitled "TILED ROOF MOUNTING SYSTEMS," filed Mar.
25, 2015, the disclosure of which is incorporated by reference
herein in its entirety; and U.S. Provisional Patent Application
Ser. No. 62/187,995, entitled SOLAR PANEL INSTALLATION SYSTEMS AND
METHODS," filed Jul. 2, 2015, the disclosure of which is
incorporated by reference herein in its entirety. This application
is related to U.S. patent application Ser. No. ______ filed Aug. 5,
2015, bearing Attorney Docket No. REC0010US2, the disclosure of
which is incorporated by reference herein in its entirety, and U.S.
patent application Ser. No. ______ filed Aug. 5, 2015, bearing
Attorney Docket No. REC0010US3, the disclosure of which is
incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] Solar panel installations typically require framed solar
panels, or modules, mounted on complex base structures assembled
from posts, rails, clamps, and other fasteners. A significant
portion of the cost of these solar panel installations may be
attributed to the rails, which are often very long extruded or
roll-formed members. Aside from the cost of manufacturing the
rails, their considerable length can add to the cost of shipping
materials to the installation site and add difficulty to the
installation process. Accordingly, railless solar panel
installation systems could beneficially reduce the costs of
manufacturing, shipping, and installing solar panels.
SUMMARY OF THE DISCLOSURE
[0003] The solar panel installation systems disclosed herein may
include an array of solar modules suspended above an installation
surface using a number of height-adjustable base members. The
height-adjustable base members may be attached to the installation
surface and used to support the solar modules at desired levels
above the installation surface.
[0004] A height-adjustable base member may include a leveling
mechanism coupled to a base plate that may be affixed to the
installation surface with one or more fasteners. A slidable
attachment member configured to engage a lip of a solar module may
be physically coupled to the top of the leveling mechanism to
attach the solar modules to the height-adjustable base member.
[0005] Adjacent solar modules may be attached to one another at or
near their corners using module links, thereby transforming the
individual module frames into a system-wide structural members that
help spread local loads throughout the system thereby reducing or
eliminating the need for separate mounting rails. The module links
may be attached to two or more solar modules and secured in place
using mid clamps clamped between adjacent solar modules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For a fuller understanding of the inventive embodiments,
reference is made to the following description taken in connection
with the accompanying drawings in which:
[0007] FIG. 1 shows a schematic top plan view of a solar panel
installation system, in accordance with various embodiments;
[0008] FIGS. 2A-2C show schematic cross-sectional views of a solar
panel installation system, including several solar modules being
mounted to an installation surface using height-adjustable base
members and slidable attachment members, in accordance with various
embodiments;
[0009] FIG. 3 shows a perspective view of a solar module supported
by a height-adjustable base member, in accordance with various
embodiments;
[0010] FIG. 4 shows an exploded view of a portion of a
height-adjustable base member, in accordance with various
embodiments;
[0011] FIG. 5 shows an exploded view of a height-adjustable base
member, in accordance with various embodiments;
[0012] FIG. 6 shows an exploded view of a height-adjustable base
member and slidable attachment member, in accordance with various
embodiments;
[0013] FIG. 7 shows a detailed perspective view of a slidable
attachment member, in accordance with various embodiments;
[0014] FIG. 8 shows a side elevation view of a frame retained
within a slot of a slidable attachment member, in accordance with
various embodiments;
[0015] FIG. 9 shows a side front elevation view of a slidable
attachment member mounted on a height-adjustable base member, in
accordance with various embodiments;
[0016] FIG. 10 shows a perspective view of a slidable attachment
member mounted on a height-adjustable base member, in accordance
with various embodiments;
[0017] FIG. 11A shows a perspective view of a height-adjustable
base member coupled to a slidable attachment member, in accordance
with various embodiments;
[0018] FIG. 11B shows a perspective view of a height-adjustable
base member coupled to a slidable attachment member, in accordance
with various embodiments;
[0019] FIG. 12 shows an exploded view of a portion of a
height-adjustable base member, in accordance with various
embodiments;
[0020] FIG. 13 shows a partially exploded view of a
height-adjustable base member, in accordance with various
embodiments;
[0021] FIG. 14 shows a front elevation view of a height-adjustable
base member coupled to a slidable attachment member, in accordance
with various embodiments;
[0022] FIG. 15 shows a partially exploded view of a slidable
attachment member coupled to a height-adjustable base member, in
accordance with various embodiments;
[0023] FIG. 16 shows a side elevation view of a height-adjustable
base member coupled to a slidable attachment member and module
frames retained in the slidable attachment member, in accordance
with various embodiments;
[0024] FIG. 17 shows a side elevation view of a height-adjustable
base member coupled to a slidable attachment member and a single
module frame retained in a slidable attachment member, in
accordance with various embodiments;
[0025] FIG. 18A shows a perspective view of a module frame and a
module link retained in a slidable attachment member, in accordance
with various embodiments;
[0026] FIG. 18B shows a perspective view of a module frame retained
in a slidable attachment member, in accordance with some
embodiments;
[0027] FIG. 18C shows a perspective view of a spacer, in accordance
with various embodiments;
[0028] FIG. 19A shows a perspective view of a portion of a solar
panel installation system, in accordance with some embodiments;
[0029] FIG. 19B shows a perspective view of an end cap, in
accordance with various embodiments;
[0030] FIG. 20A shows a perspective view of an L-foot base, in
accordance with various embodiments;
[0031] FIG. 20B shows a perspective view of an L-foot 323, in
accordance with various embodiments;
[0032] FIG. 20C shows a perspective view of an arm, in accordance
with various embodiments;
[0033] FIG. 21A shows a perspective view of a rail, in accordance
with various embodiments;
[0034] FIG. 21B shows a perspective view of a wedge, in accordance
with various embodiments;
[0035] FIG. 22 shows a partially exploded perspective view of a
height-adjustable base member coupled to a slidable attachment
member, in accordance with some embodiments;
[0036] FIG. 23 shows a perspective view of a solar panel
installation system, in accordance with various embodiments;
[0037] FIG. 24 shows an exploded view of a portion of a
height-adjustable base member, in accordance with various
embodiments;
[0038] FIG. 25 shows a detailed perspective view of an L-foot base,
in accordance with various embodiments;
[0039] FIG. 26 shows an exploded perspective view of a solar panel
installation system, in accordance with various embodiments;
[0040] FIG. 27 shows a detailed perspective view of an L-foot, in
accordance with various embodiments;
[0041] FIGS. 28 and 29 show cross sectional views of a portion of a
solar panel installation system, in accordance with some
embodiments;
[0042] FIG. 30 shows an exploded view of a module retaining
assembly, in accordance with various embodiments;
[0043] FIG. 31 shows a side view of a solar module attached to a
height-adjustable base member, in accordance with some
embodiments;
[0044] FIG. 32 shows a side view of two solar modules located in
the middle of an array attached to a height-adjustable base member,
in accordance with various embodiments;
[0045] FIGS. 33A and 33B show perspective views of a solar panel
installation system, in accordance with various embodiments, in
accordance with various embodiments;
[0046] FIGS. 34-37 show perspective views of a solar panel
installation system employing spacers, in accordance with various
embodiments;
[0047] FIG. 38 shows a perspective view of a tiled roof mounting
system for securing a solar panel system to a surface, in
accordance with some embodiments;
[0048] FIG. 39 shows a perspective view of a base plate being
coupled to a structural member of a supporting surface, in
accordance with various embodiments;
[0049] FIG. 40 shows an exploded perspective view of a mounting
tile being lowered into place over a mounting fin, in accordance
with some embodiments;
[0050] FIG. 41A shows a perspective view of a junction box
installed over a base plate with a junction box L-foot, in
accordance with various embodiments;
[0051] FIG. 41B shows a perspective view of a junction box L-foot,
in accordance with various embodiments;
[0052] FIG. 41C shows a perspective view of a junction box, in
accordance with various embodiments;
[0053] FIGS. 42A and 42B show perspective views of wire a
management assembly, in accordance with various embodiments;
[0054] FIGS. 43A-43C show perspective views of wires routed in a
wide range of directions with respect to an L-foot, in accordance
with various embodiments; and
[0055] FIG. 44 shows a flowchart of an exemplary process 400 for
assembling a solar panel installation, in accordance with some
embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] FIG. 1 shows a schematic top plan view of solar panel
installation system 100, in accordance with various embodiments.
System 100 may include an array of solar modules 110 mounted above
installation surface 102 using a number of height-adjustable base
members 120. Adjacent solar modules may be coupled together at or
near their corners using module links 140.
[0057] Solar modules 110 may each include an array of
electricity-generating solar cells covered with a protectant
material, such as tempered glass or a laminate material, for
example. The array of solar cells may be supported underneath and
enclosed about the perimeter with a frame. Solar modules 110 are
typically rectangular-shaped structures having four corners but
other shapes are possible and explicitly contemplated for use with
the embodiments disclosed herein.
[0058] Solar modules 110 may be supported above installation
surface 104, which may be a roof or the ground, for example, using
height-adjustable base members 120. Height-adjustable base members
120 can attach to the frames of solar modules 110 at locations
along their edges. Depending on environmental and regulatory
requirements, a suitable number of height-adjustable base members
120 can be provided along each edge of each solar module 110. For
example, a single height-adjustable base member 120 may be provided
along each long edge of solar modules 110 with zero members being
provided along each short edge, as shown in FIG. 1. In another
example, two height-adjustable base members 120 may be provided
along each long edge of solar modules 110 with one member being
provided along each short edge.
[0059] Height-adjustable base members 120 may be height-adjustable
in order to level the array of solar modules 110, taking into
account irregularities in installation surface 104 and/or in the
frames of solar modules 110. In some embodiments, height-adjustable
base members 120 may also provide a tilt for the array of solar
modules 110 to increase their exposure to sunlight.
Height-adjustable base members 120 may also be physically coupled
to installation surface 104. In some embodiments, height-adjustable
base members 120 may be secured to structural members of
installation surface 104, such as roof rafters 106, for
example.
[0060] As depicted in FIG. 1, solar modules 110 may be arranged in
a grid-shaped array with each corner solar module being edgewise
adjacent to two other solar modules and diagonally adjacent to one
other solar module, each non-corner edge solar module being
edgewise adjacent to three other solar modules and diagonally
adjacent to two other solar modules, and each interior solar module
being edgewise adjacent to four other solar modules and diagonally
adjacent to four other solar modules. Locations in the array where
the corners of solar modules 110 are closest to one another in the
array may be referred to herein as intersections.
[0061] Solar modules 110 may be attached to one another at or near
their corners using module links 140. Module links 140 may attach
to the frames of solar modules 110 to provide structural coupling
between the any two edgewise adjacent solar modules 110 or all four
adjacent solar modules at each interior intersection and between
two edgewise adjacent solar modules 110 at each edge intersection.
Coupling solar modules 110 together in this manner can transform
the array of independent solar modules 110 into a single structural
member that advantageously spreads loads throughout system 100,
thereby reducing or eliminating the need for long, expensive
mounting rails.
[0062] FIGS. 2A-2C show schematic cross-sectional views of system
100, including several solar modules 110 being mounted to
installation surface 104 using height-adjustable base members 120
and slidable attachment members 130, in accordance with various
embodiments. In particular, FIGS. 2A-2C depict a typical
installation progression for system 100 in which a solar module
(i.e., solar module 110a) is brought into engagement with a first
slidable attachment member 130a mounted above height-adjustable
base member 120a, rotated down toward a second slidable attachment
member 130b mounted above height-adjustable base member 120b, and
the solar module being locked into place by virtue of at least one
component of slidable attachment member 130 retaining the frame of
module 110a. All modules in the array can be installed using the
same general procedure.
[0063] It should be understood that while FIGS. 2A-2C depict
height-adjustable base member 120 and slidable attachment member
130, the same basic installation method and module array
configuration depicted here is applicable to the various
height-adjustable base member and slidable attachment member
embodiments disclosed herein. Furthermore, although certain
height-adjustable base members and slidable attachment members are
depicted and described in conjunction in the following descriptions
and drawings, one of skill in the art will appreciate that in some
embodiments, the height-adjustable base members and slidable
attachment members can be interchanged (e.g., height-adjustable
base member 220 can support slidable attachment member 330,
height-adjustable base member 420 can support slidable attachment
member 230, etc.).
[0064] FIG. 3 shows a perspective view of solar module 110
supported by height-adjustable base member 120, in accordance with
various embodiments. Height-adjustable base member 120 may include
height-adjustable support mechanism 126 extending away from base
plate 121, which may be placed on and physically coupled to an
installation surface (e.g., installation surface 104 of FIG. 1) as
described in detail below. Height-adjustable support mechanism 126
may be shaped to slidably receive slidable attachment member 130,
which may, in turn, slidably receive a portion (e.g., a flange) of
frame 112 of solar module 110. Accordingly, height-adjustable base
member 120 can support an edge of solar module 110 above the
installation surface in a height-adjustable manner.
[0065] Because slidable attachment member 130 travels with respect
to height-adjustable base member 120, it provides tolerance to
adjust the point where slidable attachment member 130 attaches to
frame 112. In particular, for the rail-less installations disclosed
here, it may not be possible to determine in advance where a module
frame will land relative to the roofing "courses" or rows of
shingles. On composition roofs, for example, it is common for
courses to be separated by approximately 5 inches (12.7 cm), so
slidable attachment members having approximately 6 inches (15.2 cm)
of travel in either direction can provide the required tolerance.
On tile roofs, shingles tend to repeat approximately every 13
inches (33 cm). For this reason, a tile base plate can be provided
with ribs stamped into the flashing. Because the height-adjustable
base member may be installed at any point along the rib, these ribs
allow the slidable attachment member more travel (e.g.,
approximately 6 inches (15.2 cm)) for the height-adjustable base
members, thereby allowing them to cover the range of locations that
may be required of them without limiting the allowable positions
for solar module placement. Tile replacement embodiments are
disclosed below with respect to FIGS. 38-41.
[0066] FIG. 4 shows an exploded view of a portion of
height-adjustable base member 120, in accordance with various
embodiments, including base plate 121, with raised portion 121a and
aperture 121b formed in raised portion 121a, o-ring 122, washer
123, post 124, and fastener 125. O-ring 122 may be a compressible
gasket that can be placed underneath base plate 121 between raised
portion 121a and the installation surface. O-ring 122 can include
an aperture coincident with aperture 121b of base plate 121 to
receive fastener 125. O-ring 122 may thereby seal height-adjustable
base member 120 in a water-tight manner to prevent moisture from
reaching the installation surface under base plate 121.
[0067] Post 124 may extend substantially perpendicularly away from
base plate 121 in a direction opposing the installation surface.
Post 124 can be a hollow cylindrically-shaped member that can
receive fastener 125, which may be any suitable fastener, such as a
nail, a screw, or a lag bolt, in accordance with various
embodiments. Fastener 125 can extend through an aperture with a
smaller diameter than the outer diameter of post 124 in order to
secure post 124 to base plate 121 and base plate 121 to the
installation surface. Washer 123 may be provided between fastener
125 and the aperture of post 124 and may be a traditional washer or
a sealing-gasket in accordance with various embodiments.
[0068] FIG. 5 shows an exploded view of height-adjustable base
member 120, in accordance with various embodiments. In particular,
FIG. 5 shows height-adjustable support mechanism 126 ready to be
mounted on the portion of height-adjustable base member 120 shown
in FIG. 4, now assembled. Height-adjustable support mechanism 126
may include hollow cylindrically-shaped member 126a, which may be
configured to concentrically receive post 124 such that
height-adjustable support mechanism 126 can be slid longitudinally
along the length of post 124. Height-adjustable support mechanism
126 may include a longitudinal split running part of its length.
The slit may be part of clamping mechanism 126b, having two flanges
extending substantially perpendicularly away from hollow
cylindrically-shaped member 126a, with one flange positioned on
each side of the slit. Each flange may also include an aperture
configured to receive fastener 127. In some embodiments, one or
both of the apertures may be threaded and configured to threadably
receive a threaded fastener 127
[0069] Tightening fastener 127 within the apertures can cause the
flanges to approach one another, thereby reducing the width of the
slit and the circumference of hollow cylindrically-shaped member
126a. Using clamping mechanism 126, the circumference of hollow
cylindrically-shaped member 126a may be reduced to a size that
approaches the outer circumference of post 124, thus clamping
height-adjustable support mechanism 126 to a desired position on
post 124. In some embodiments, the exterior surface of post 124 and
the interior surface of hollow cylindrically-shaped member 126a may
be provided with ridges that can promote engagement therebetween
and resist relative motion when height-adjustable support mechanism
126 is in clamped engagement with post 124.
[0070] Height-adjustable support mechanism 126 may further include
features for receiving and locking in place slidable attachment
member 130. For example, locking member 126c may be configured to
slidably engage slidable attachment member 130 such that slidable
attachment member 130 may move in substantially one dimension with
respect to height-adjustable support mechanism 126. Locking member
126c may include an aperture formed through a fastener receiving
surface and a sloped surface extending obliquely from a top surface
of locking member 126c toward he fastener receiving surface, where
the aperture is configured to receive a fastener that further
restricts relative movement of slidable attachment member 130 in
its otherwise free dimension.
[0071] Sliding member 126d, situated on an opposing side of hollow
cylindrically-shaped member 126a, may be similar to locking member
126c with the exception of the aperture. In some embodiments,
however, sliding member 126d may be configured as a second locking
member.
[0072] FIG. 6 shows an exploded view of height-adjustable base
member 120 and slidable attachment member 130, in accordance with
various embodiments. In particular, FIG. 6 shows height-adjustable
base member 120 fully assembled and ready to receive slidable
attachment member 130.
[0073] Slidable attachment member 130 can include C-shaped sliding
portion 132 configured to slidably couple to locking member 126c
and sliding member 126d of height-adjustable support mechanism 126.
The walls and flanges of C-shaped sliding portion 132 permit
slidable engagement between slidable attachment member 130 and
height-adjustable base member 120 in substantially only one
direction. Fastener 134 may be inserted the aperture of locking
member 126c and into a threaded aperture formed in wedge 126e in
order to secure slidable attachment member 130 to height-adjustable
base member 120 by preventing relative movement between the two
components in the otherwise free dimension. In particular, a sloped
surface of wedge 126e, can be brought into engagement with the
complementary sloped surface of locking member 126c. When fastener
134 is tightened in the threaded aperture of wedge 126e, wedge 126e
slides against locking member 126c in a direction towards the
installation surface. In this way, wedge 126e can clamp down on an
end of C-shaped sliding portion 132 to lock slidable adjustment
member 130 in place relative to height-adjustable base member
120.
[0074] FIG. 7 shows a detailed perspective view of slidable
attachment member 130, in accordance with various embodiments. In
particular, FIG. 7 shows frame-engagement slots 136a-c and clips
138a-c, which may be configured to receive a flange of a solar
module frame, such as flange 112a of frame 112. Each slot/clip
combination (e.g., slot 136a and clip 138a) can receive and retain
a flange of a solar module frame, thereby attaching the frame to
height-adjustable base member 120 and the installation surface.
[0075] Slidable attachment member 130 can attach solar modules 110
to height-adjustable base members 120 at both interior and exterior
positions in system 100. As depicted in FIG. 6, slot 136c and clip
138c may be configured to retain frame 112 positioned on the
perimeter of the array of solar modules 110 of FIG. 1). Slots 136a
and 136b and clips 138a and 138b, on the other hand, may be used to
retain the frames of two edgewise adjacent solar modules 110
located in the interior of the array. Advantageously, this means
that slidable attachment member 130 may be of identical
construction regardless of its position in the array.
[0076] In some embodiments, slidable attachment member 130 may be a
punched and roll-formed member. That is, slidable attachment member
130 may be formed from a single piece of sheet metal that is
stamped and then bent and folded to form both C-shaped sliding
portion 132 and slots 136a-136c. Clips 138a-136c may also be
stamped and bent into shape from the original piece of sheet metal
or they may be formed separately and attached in a separate
post-processing step.
[0077] FIG. 8 shows a side elevation view of frame 112 retained
within slot 136a of slidable attachment member 130, in accordance
with various embodiments. Also visible in this side elevation view
is slidable attachment member 130 mounted on height-adjustable base
member 120. FIG. 9 shows a side front elevation view of slidable
attachment member 130 mounted on height-adjustable base member 120,
in accordance with various embodiments. FIG. 10 shows a perspective
view of slidable attachment member 130 mounted on height-adjustable
base member 120, in accordance with various embodiments.
[0078] FIG. 11A shows a perspective view of height-adjustable base
member 220 coupled to slidable attachment member 230, in accordance
with various embodiments. Height-adjustable base member 220 may be
functionally similar to height-adjustable base member 120, so it
can provide a height-adjustable support for a slidable attachment
member. Height-adjustable base member 220 can differ from
height-adjustable base member 120, however, in that some or all of
its component parts may be extruded rather than stamped and
roll-formed.
[0079] Height-adjustable base member 220 includes base plate 221,
which may include raised-portion 221a arranged over L-foot base
222. L-foot base 222 may be secured to an installation surface or a
structural member supporting the installation surface, such as roof
rafter 206, for example, using fastener 222a, which can extend
through aperture 222c formed in L-foot base 222 under a domed
section of raised portion 221. Threaded stud 222b can extend
substantially perpendicularly away from L-foot base 222 in a
direction opposing the installation surface.
[0080] L-foot 223 may be coupled to L-foot base 222 using threaded
stud 222b, which may extend through an aperture in the horizontally
arranged section of L-foot 223, and nut 223a, which can threadably
engage threaded stud 222b. Threaded stud 222b may also extend
through an aperture formed in a flat section of raised portion
221b, which may be secured between the horizontally arranged
section of L-foot 223 and L-foot base 222, thereby coupling base
plate 221 to the installation surface. In some embodiments, the
horizontally arranged section of L-foot 223 may be shaped to match
the contours of L-foot base 222 and the flat portion of raised
section 221a.
[0081] The vertically arranged section of L-foot 223 may include
longitudinal slit 223b formed along at least a portion of its
length. Longitudinal slit 223b may be configured to receive
fastener 223c for adjustably coupling arm 224 to a surface of the
vertically arranged portion of L-foot 223. The surface of the
vertically arranged portion of L-foot 223 and the mating surface of
arm 224 may be ribbed or otherwise textured to prevent arm 224 from
moving with respect to L-foot 223 when the two components are
coupled together with fastener 223c.
[0082] Arm 224 may be coupled to and support the weight of slidable
attachment member 230. Slidable attachment member 230 can include
rail 232 and module retaining assemblies 234 coupled to rail 232.
Module retaining assemblies 234 may be used to receive and retain
solar module frames as described in more detail below.
[0083] FIG. 11B shows a perspective view of height-adjustable base
member 220 coupled to slidable attachment member 230 as depicted in
FIG. 11A with the exception that arm 224' has a mating surface
configured to interlock with the surface of the vertical portion of
L-foot 223. The interlocking features of arm 224' may wrap
partially around the vertical portion of L-foot 223 to prevent arm
224' from twisting while fastener 223 is tightened.
[0084] FIG. 12 shows an exploded view of a portion of
height-adjustable base member 220, in accordance with various
embodiments. In particular, FIG. 12 depicts L-foot base 222,
including threaded stud 222b, coupleable to roof rafter 206 with
fastener 222a. Fastener 222a may be accommodated beneath the domed
section of raised portion 221a of base plate 221, and threaded stud
222b may extend through the aperture in the flat section of raised
portion 221a. The aperture formed in the horizontally arranged
section of L-foot 223 may also receive threaded stud 222b and may
be fastened to base plate 221, L-foot base 222, and roof rafter 206
using nut 223a.
[0085] FIG. 13 shows a partially exploded view of height-adjustable
base member 220, in accordance with various embodiments. In FIG.
13, it may be appreciated that arm 224 can include mating surface
224a configured to be coupled to a surface of the vertically
arranged portion of L-foot 223 with fastener 223c, which may extend
through slit 223b and into a threaded bore formed through mating
surface 224a. Mating surface 224 and the surface of the vertically
arranged portion of L-foot 223 are depicted as having
complementarily ribbed surfaces to facilitate slip-free coupling
between arm 224 and L-foot 223.
[0086] Arm 224 may be generally L-shaped, with mating surface 224a
arranged at the end of the horizontally arranged portion of the L.
On the vertically arranged portion of the L, arm 224 may include
flanges 224b, which can be configured to mate with complementary
flanges of rail 232 and disclosed in more detail below. Flanges
224b may be angled towards the installation surface in order to
prevent movement of rail 232 in a direction opposing the
installation surface.
[0087] At the top, distal end of the L, arm 224 may include two
sloped surfaces 224c. Wedges 225a and 225b, which may assist in
supporting rail 232, can each be placed with a complementarily
sloped edge against a respective one of sloped surfaces 224c.
Sloped surfaces 224c may be separated from one another by a
distance suitable to receive fastener 225d, which can extend
through threaded bores in wedges 225a and 225b to couple the wedges
together. As fastener 225d is tightened, wedges 225a and 225b may
move towards each other, sliding against sloped surfaces and moving
together in a direction opposing the installation surface. In some
embodiments, only wedge 225b may be provided with a threaded bore,
in which case fastener 223d can be inserted first into wedge 225a,
without the threaded bore, and then threaded into the threaded bore
of the wedge 225b.
[0088] FIG. 14 shows a front elevation view of height-adjustable
base member 220 coupled to slidable attachment member 230, in
accordance with various embodiments. In particular, FIG. 14 shows
flanges 232a of rail 232 engaged with the complementary flanges
224b of arm 224. Engagement of flanges 224b with flanges 232a may
permit slidable attachment member 230 one dimensional movement with
respect to arm 224, in a direction substantially parallel with the
installation surface.
[0089] Once flanges 224b are moved into engagement with flanges
232a, fastener 225c may be tightened, moving wedges 225a and 225b
into engagement with horizontal surface 232b of rail 232, pulling
flanges 232a against flanges 224b, and generally resisting movement
of rail 232 with respect to arm 224. To further resist movement of
rail 232 with respect to arm 224, one or more of the surfaces of
flanges 232a, flanges 224b, wedges 225a and 225b, and horizontal
surface 232b may be ridged or otherwise textured.
[0090] Rail 232 may further include L-shaped flanges 232c extending
substantially perpendicularly from horizontal surface 232b in a
direction opposing the installation surface. Flanges 232c may be
inwardly facing L-shaped members that may serve to retain the head
of fastener 237. Fastener 237 may then serve as a mounting point
for module retaining assembly 234.
[0091] Module retaining assembly 234 may include lip bracket 236
and spring clip 235. Lip bracket 236 may be a generally W-shaped
member with the hump of the W configured to rest atop flanges 232c
of rail 232. An aperture formed in the hump may be configured to
accept fastener 237.
[0092] Spring clip 235 may be a two-sided clip structure having a
flat central section and two clips extending from the flat central
section. The flat central section of spring clip 235 may rest atop
the hump of lip bracket 236 and include an aperture substantially
coincident with the aperture of lip bracket 236 configured to
receive fastener 237. Nut 237a may threadably engage fastener 237
in order to secure lip bracket 236 and spring clip 235 to rail
232.
[0093] FIG. 15 shows a partially exploded view of slidable
attachment member 230 coupled to height-adjustable base member 220,
in accordance with various embodiments.
[0094] FIG. 16 shows a side elevation view of height-adjustable
base member 220 coupled to slidable attachment member 230 and
module frames 112 retained in slidable attachment member 230, in
accordance with various embodiments. As may be appreciated with
reference to FIG. 16, lip brackets 236 may include an extended
portion that creates slots 236a-236d, which may be configured to
receive frame flange 112a of frame 112. Frame flanges 112a may also
be retained under clip ends of spring clips 235. The configuration
depicted in FIG. 16 may be representative of height-adjustable base
member 220 being used to support two solar modules (not shown)
supported by frames 112 at an interior position of a solar module
array, such as system 100 of FIG. 1.
[0095] FIG. 17 shows a side elevation view of height-adjustable
base member 220 coupled to slidable attachment member 230 and a
single module frame 112 retained in slidable attachment member 230,
in accordance with various embodiments. The configuration depicted
in FIG. 17 may be representative of height-adjustable base member
220 being used to support a single solar module (not shown)
supported by frame 112 at an exterior position of a solar module
array, such as system 100 of FIG. 1.
[0096] FIG. 18A shows a perspective view of module frame 112 and
module link 140 retained in slidable attachment member 230, in
accordance with some embodiments. As noted above, module links 140
may attach to module frames 112 to provide structural coupling
between the adjacent solar modules. As depicted in FIG. 18A, module
link 140 may be a C-shaped member that can generally surround
module frame 112 on three sides in a nested configuration. Thus,
frame flange 112a can rest atop lower flange 140a of module link
140, and both frame flange 112a and lower flange 140a may be
retained in slidable attachment member 234. For example, frame
flange 112a and lower flange 140a may be slid into a slot of lip
bracket 236 and retained in place with spring clip 235.
[0097] FIG. 18B shows a perspective view of module frame 112
retained in slidable attachment member 230, in accordance with some
embodiments. In particular, FIG. 18B is similar in all respects to
FIG. 18A, except that module link 140 is omitted. In place of lower
flange 140a of module link 140, spacer 238 can be provided between
frame flange 112a and rail 232. Spacer 238 can raise frame flange
112a to substantially the same height as it would rest if supported
by lower flange 140a as in FIG. 18A.
[0098] FIG. 18C shows a perspective view of spacer 238, in
accordance with various embodiments. Spacer 238 can include flanged
walls 238b extending away from spacing member 238a. The thickness
of spacing member 238a can be chosen to raise frame flange 112a to
substantially the same height as it would rest if supported by
lower flange 140a as in FIG. 18A. Spacer 238 may also include
aperture 238c and string line features to facilitate removal from
rail 232. Using spacer 238 in this manner can ease installation in
a number of ways. First, the use of spacer 238 can permit an
installer or manufacturer to assemble slidable attachment members
230 in advance regardless of whether the component will be used to
retain frame flange and module link or only a frame flange. At
installation time, spacer 238 can be added whenever a module link
is not present omitted when a module link is present. Second, using
spacer 238 to elevate frame flange 112 when no module link is
present avoids the need for differently sized retaining assemblies
234 for frame only locations and for frame plus module link
locations.
[0099] FIG. 19 shows a perspective view of a portion of solar panel
installation system 200, in accordance with some embodiments.
System 200 may include solar modules 110 coupled together with
module link 140 and supported by height-adjustable base members
220a and 220b. Height-adjustable base member 220a is placed
vertically below module link 140, as in the view provided in FIG.
18A while height-adjustable base member 220b is placed below module
frame 112 at a position not covered by module link 140, as in the
view provided in FIG. 18B. Accordingly, spacer 238 may be provided
between the rail and the slidable adjustment member mounted above
height-adjustable base member 220b and omitted above
height-adjustable base member 220a.
[0100] Furthermore, FIG. 19A depicts the ends of rails 232 being
covered by end caps 233, which may enhance the aesthetics of system
200. It should be understood that end caps, such as end caps 233,
may be provided for use with any of the embodiments disclosed
herein. In some embodiments, end caps 233 may be configured to
slidably and/or snappingly engage the ends of rails 232. End caps
233 may additionally or alternatively be coupled to rails 232 with
one or more fasteners, adhesives, or combinations thereof.
[0101] FIG. 19B shows a perspective view of end cap 233, in
accordance with various embodiments.
[0102] FIG. 20A shows a perspective view of L-foot base 322, which
can embody an alternate implementation of L-foot base 222, in
accordance with various embodiments. L-foot base 322 may, like
L-foot base 222, include threaded stud 322b and aperture 322c.
Additionally, or as an alternative to aperture 322c, L-foot base
322 can include apertures 322d-322g, for receiving fasteners in the
event that L-foot base 322 is being fastened to an I-beam shaped
joist, such as an I-joist, or a TJI joist, for example.
Furthermore, teeth 322h may be formed on the side of L-foot base
322 configured to contact the installation surface in order to
prevent twisting of L-foot base 322 with respect to the
installation surface during and after installation.
[0103] FIG. 20B shows a perspective view of L-foot 323, which can
embody an alternate implementation of L-foot 223, in accordance
with various embodiments. In particular, L-foot 323 can include
leveling marks 323d running perpendicular to the longitudinal
direction of longitudinal slit 323b. Leveling marks 323d can
provide an installer with a visual reference point for determining
the proper vertical installation position of arm 224. Although not
depicted in FIGS. 20B and 20C, L-foot 323 and arm 324 can include
complementarily ribbed surfaces to facilitate slip-free coupling,
like arm 224 and L-foot 223.
[0104] FIG. 20C shows a perspective view of arm 324, which can
embody an alternate implementation of arm 224 or arm 324, in
accordance with various embodiments. Extending from the
interlocking portions of the mating surface of arm 324 can include
leveling indicators 324d. When arm 324 is installed, leveling
indicators 324d may be visible on either side of leveling marks
323d. Therefore, leveling indicators 324d may provide a visual
reference point on arm 324 to be compared with leveling marks 323d
of L-foot 323 to aid the leveling process during installation.
[0105] FIG. 21A shows a perspective view of rail 332, which can
embody an alternate implementation of rail 232, in accordance with
various embodiments. In contrast with rail 232, which has a stepped
profile between L-shaped flanges 232a and L-shaped flanges 232c on
either side of horizontal surface 232b, rail 332 can smoothly
transition between L-shaped flanges 332a and L-shaped flanges 332c
on either side of horizontal surface 332b. In comparison with rail
232, rail 332 may be formed with less material and provide better
alignment with arm 324 having leveling indicators 324d.
[0106] FIG. 21B shows a perspective view of wedge 325a, which can
embody an alternate implementation of wedge 225a, in accordance
with various embodiments. In contrast with wedge 225a, wedge 325a
can include a feature that visually distinguishes it from wedge
225b. As depicted, that feature can be extended portion 325d,
which, when installed, can extend from the body of wedge 325
towards the installation surface. Extended portion 325d may form a
stop against the side of an arm (e.g., arm 224, arm 224', or arm
324) to prevent wedge 325a from moving too close to wedge 225b,
which may interfere with the installation of rail 232 or rail 332
over height-adjustable base member 220.
[0107] FIG. 22 shows a partially exploded perspective view of
height-adjustable base member 320 coupled to slidable attachment
member 330, which can embody alternate implementations of
height-adjustable base member 220 and sliadable attachment member
230, respectively, in accordance with some embodiments. For
example, height-adjustable base member 320 coupled to slidable
attachment member 330 can include rail 332, wedges 325, L-foot base
322, L-foot 323, arm 324, and various other components described
below that are not included in height-adjustable base member 220 or
slidable attachment member 230.
[0108] As may be appreciated with reference to FIG. 22, leveling
indicators 324d can visually indicate the mounting point of arm 324
with respect to leveling marks 323d of L-foot 332. This visual
indication can aid installers by providing visual cues to help
ensure consistently level installation.
[0109] Module retaining assemblies 334 may be functionally similar
to module retaining assemblies 234 insofar as they may be used to
retain module frames as discussed in more detail below. However,
module retaining assembly 334 can include a number of components
not present in module retaining assembly 234, including rotation
key 336, spring clip 335, clamping stop 339, and resilient cap
331.
[0110] Rotation key 336 can include rail engaging walls 336a,
horizontal member 336b, and locking walls 336c. Rail engaging walls
336a, which may run substantially parallel to one another, can
extend substantially parallel from horizontal member 336b in a
direction toward the installation surface, as installed. These rail
engaging walls may be spaced apart from one another by a distance
suitable to cause engagement with the outer sides of L-shaped
flanges 332c, thereby preventing rotation of rotation key 336 with
respect to rail 332. In alternative embodiments, rail engaging
walls 336a may be spaced to fit between, and may include features
that clip into, L-shaped flanges 332c.
[0111] Horizontal member 336b can rest atop L-shaped flanges 332c,
or spacers 338 if provided, when rotation key 336 is engaged with
rail 332. Fastener 337 can extend substantially perpendicularly
away from horizontal member 336b in a direction away from the
installation surface, as installed. Fastener 337, according to
various embodiments, may be a traditional threaded fastener with a
head and a threaded shaft, or it may be a threaded stud integrally
formed with, or coupled to rotation key 336.
[0112] Also extending substantially perpendicularly away from
horizontal member 336b in a direction away from the installation
surface, as installed, are locking walls 336c. Locking walls 336c
may run substantially parallel to one another and can be spaced
apart by a distance suitable to receive, with little or no play,
features of spring clip 335 and clamping stop 339. By receiving
spring clip 335 and clamping stop 339 between locking walls 336c,
rotation key 336 can prevent location of the entirety of module
retaining assembly 334 with respect to rail 332 when installed.
[0113] Module retaining assembly 334 may include spring clip 335,
which, like spring clip 235, can include a flat central section and
two clips extending from the flat central section. The flat central
section of spring clip 335 may rest atop horizontal member 336b and
include an aperture substantially coincident with an aperture of
rotation key 336 configured to receive fastener 337. The width of
the flat central section of spring clip 335, as measured transverse
to the direction in which the clips extend, may be substantially
similar to the spacing of locking walls 336c such that the flat
central section non-rotatingly engages locking walls 336c.
[0114] Clamping stop 339 may rest atop spring clip 335 to exert a
force directed toward the installation surface on the clips of
spring clip 335 and to support a solar module above the upper
bounds of rail 332. Accordingly, clamping stop 339 can include a
first side arranged closest to the installation surface, as
installed, having a flat central section that engages the flat
central section of spring clip 335, two flanges that exert the
force on the clips of spring clip 335, and an aperture extending
from the flat central section to a second side of the clamping
stop. The second side of the clamping stop may generally face away
from the installation surface, as installed, and can include one or
more features, such as a mesa extending away from the second side,
for example, for receiving resilient cap 331 (e.g., with an
interference fit). Resilient cap 331 may also be coupled to
clamping stop 339 with one or more of a fastener, clip, or adhesive
and may protect the back surface of a solar module installed upon
slidable attachment member 330. Fastener 337 may extend through the
aperture of clamping stop 339, and nut 337a may threadably engage
fastener 337 in order to secure clamping stop 339 and spring clip
335 to rail 332.
[0115] FIG. 23 shows a perspective view of system 400, including
solar module 110 supported by height-adjustable base member 420, in
accordance with various embodiments. Height-adjustable base member
is configured to be installed on an installation surface using an
aperture-less flashing--namely, base plate 421. Height-adjustable
base member 420 may slidably receive slidable attachment member
430, which may, in turn, slidably receive a portion (e.g., a
flange) of frame 112 of solar module 110. Accordingly,
height-adjustable base member 120 can support an edge of solar
module 110 above the installation surface in a height-adjustable
manner. Advantageously, system 400 does not require any holes to be
made in the flashing, which can significantly reduce the potential
for moisture to reach installation surface 104 below base plate 421
thereby eliminating a major source of leaks in commercial and
residential roof-mounted solar panel installations.
[0116] FIG. 24 shows an exploded view of a portion of
height-adjustable base member 420, in accordance with various
embodiments. In particular, FIG. 24 depicts L-foot base 422
coupleable to roof rafter 406 (or other suitable structural member)
with fastener 422a. Fastener 422a can be inserted through apertures
422c formed in L-foot base 422 and can be accommodated beneath
raised portion 421a of base plate 421. L-foot base 422 can also
have a keyed cross-sectional profile with keyed channels 422c that
can mate with complementarily shaped features of an L-foot. FIG. 25
shows a detailed perspective view of L-foot base 422, in accordance
with various embodiments.
[0117] FIG. 26 shows an exploded perspective view and FIGS. 28 and
29 show cross sectional views of a portion of system 400, in
accordance with some embodiments. FIG. 27 shows a detailed
perspective view of L-foot 423. As shown in FIGS. 26-29, L-foot
base 422 and raised portion 421 serve as the attachment point for
clamping L-foot 423, which may support one or more other components
of height-adjustable base member 420. Clamping L-foot 423 may
include horizontal member 423a, clamping wedge 423b,
base-engagement leg 423c, aperture 423d, vertical member 423e, and
slot 423f formed in vertical member 423e. Clamping L-foot 423 can
be coupled to L-foot base 422 through raised portion 421 using
fastener 426.
[0118] Clamping wedge 423b and base-engagement leg 423c can extend
away from horizontal member 423a in a direction approaching surface
104, as installed, with a space formed therebetween to accept
L-foot base 422 and raised portion 421. Base-engagement leg 423c
may extend substantially perpendicularly from horizontal member
423a to engage a first side of L-foot base 422 and raised portion
421. In embodiments in which L-foot base 422 has a keyed
cross-sectional profile, the wall of base engagement leg 423c that
engages L-foot base 422 may have a complementarily shaped profile
to promote engagement between base engagement leg 423c and keyed
channels 422b of L-foot base 422, thereby preventing movement of
clamping L-foot 423 relative to base plate 421, especially in a
direction extending substantially perpendicularly away from
mounting base plate 421.
[0119] Clamping wedge 423b can include a sloped surface configured
complementarily to sloped surface 424a of base-coupling wedge 424.
Fastener 426 can be inserted through aperture 423d and threadably
engage threaded aperture 424b of base-coupling wedge 424. As
fastener 426 is tightened within aperture 424b, base-engagement leg
423c and base-coupling wedge 424 may be urged towards opposing
sides of L-foot base 422, thereby coupling clamping L-foot 423 to
L-foot base 422b. As with base-engagement leg 423c, base-coupling
wedge 423 may be shaped to form a keyed fit with keyed channels
422b of L-foot base 422 to facilitate attachment therebetween. In
some embodiments, the surfaces of clamping wedge 423b and of
base-coupling wedge 424 that engage L-foot base 422 may include
vertically-aligned grooves or ridges formed complementarily with
similar grooves or ridges formed on L-foot base 422. These grooves
or ridges may prevent lateral movement of height-adjustable base
member 420 with respect to base plate 421.
[0120] Once coupled to base plate 421, clamping L-foot 423 may
serve as a mounting point for one or more other components of
system 400. For example, clamping L-foot 423 may support a slidable
attachment member 430 using a lever-locking assembly 450.
[0121] FIG. 30 shows an exploded view of module retaining assembly
434, in accordance with various embodiments. Module retaining
assembly 434 is similar to module retaining assembly 334 with the
exception that clamping stop 439 is one sided, whereas module
retaining assembly 334 includes two-sided clamping stop 339.
Additionally, fastener 437 is inserted from the top side of module
retaining assembly 434 and into a channel nut 437b retained in the
top channel of rail 432. When fastener 437 is tightened into
channel nut 437b, module retaining assembly 434 is coupled to the
top side of rail 432. In some embodiments, the head of fastener 437
and washer 437a may be retained within a recess formed in the top
side of clamping stop 437.
[0122] FIG. 31 shows a side view of solar module 110 attached to
height-adjustable base member 420, in accordance with some
embodiments. Solar module 110 of FIG. 31 is positioned at the end
of a row of solar modules. In contrast, FIG. 32 shows a side view
of two solar modules 110 located in the middle of an array attached
to height-adjustable base member 420.
[0123] FIGS. 33A and 33B show perspective views of system 400, in
accordance with various embodiments. In particular, FIGS. 33A and
33B illustrate that height-adjustable base members 420 are
reversible.
[0124] As may be appreciated with reference to FIGS. 34-37, system
400 can employ spacers 438, which may be similar to spacers 238 and
338 disclosed above.
[0125] FIG. 38 shows a perspective view of tiled roof mounting
system 500 for securing a solar panel system to a surface, in
accordance with some embodiments. Generally speaking, system 500
can include base member 510 couplable to an installation surface
502 (not visible in FIG. 38) and height-adjustable base member
coupled to base member 510. Height-adjustable base member 520 may
then serve as the mounting point for one or slidable-attachment
members 530. While the embodiments disclosed herein are
particularly suited for installing solar panel systems on a tiled
roof, it should be understood that tiled roof mounting system 500
may be used in conjunction with other installation surfaces, such
as shingled roofs, metal roofs, concrete roofs, and the like.
Accordingly, surface 502 may be the surface underlying the tiles of
a tiled roof.
[0126] FIG. 39 shows a perspective view of base plate 512 of base
member 510 being coupled to a structural member of supporting
surface 502, in accordance with various embodiments. The structural
member may be, for example, a rafter underlying surface 502 (which
has been omitted for clarity). Base plate 512 can include one or
more apertures 512a for receiving fasteners 514. Fasteners 514 may
be any suitable fasteners for coupling base plate 512 to the
structural member, including bolts, screws, nails, and the
like.
[0127] In addition to apertures 512a, base plate 512 can include
one or more tracks, namely tracks 512b. Tracks 512b may be a
substantially U-shaped structures defined by walls 512c, which can
run substantially parallel to one another and which can extend away
from base plate 512 in a direction pointing substantially
perpendicularly away from surface 502, as installed. Walls 512c may
include flanged ends configured to accept channel nuts having
complementarily-shaped flanges. The flanges of walls 512c and the
complementarily-shaped flanges of the channel nuts may permit
one-dimensional movement of the channel nuts along tracks 512b,
which can facilitate locational adjustment of mounting foot 518
with respect to base plate 512. Each channel nut can include a
threaded aperture.
[0128] Mounting foot 518 can include coupling portion 518a and
mounting portion 118b arranged substantially parallel to coupling
portion 518a. Coupling portion 118a can include number of apertures
518c for accepting fasteners 518d, which may attach mounting foot
518 to the channel nuts. The number and placement of apertures 518c
may, therefore, be dictated by the number of and lateral separation
between tracks 512b. As shown in FIG. 39, base plate 512 includes
two tracks 512b. However, base plate 512 may include any suitable
number of tracks (e.g., one, two, five, etc.). Fasteners 518d can
be inserted through apertures 518c to engage the threaded apertures
of the channel nuts. Upon threadably engaging fasteners 518d with
the threaded apertures, mounting foot 518 may be drawn against the
ends of walls 512c, and the channel nuts may be drawn against the
flanges in walls 512c, thereby locking mounting foot 518 and the
channel nuts in place.
[0129] Mounting fin 518b may be configured to receive a channel
formed in mounting tile 521. In particular, mounting fin 518b can
have a cross-sectional profile that permits the channel of mounting
tile receive mounting fin 118b in the channel. The keyed
cross-sectional profile of mounting fin 118b may take on any
suitable shape that facilitates attachment of a clamping L-foot
(e.g., clamping L-foot 423). FIG. 40 shows an exploded perspective
view of mounting tile 521 being lowered into place over mounting
fin 518b.
[0130] FIG. 41A shows a perspective view of junction box 660
installed over base plate 421 with junction box L-foot 662, in
accordance with various embodiments. Junction box 660 may protect
electrical connections made between various components of system
600. Junction box L-foot 662 may be installed over L-foot 623
(which may correspond to L-foot 223, L-foot 323, or L-foot 423, for
example) using threaded stud 622b and nut 623a. In particular,
threaded stud 622b may extend from a base member (not visible in
FIG. 41A) through an aperture in L-foot 623 and slit 662a in
junction box L-foot 662. L-foot 423 and junction box L-foot 662 can
then be secured to base plate 621 using nut 623a.
[0131] Junction box L-foot 662 may also include slot 662b for
receiving fastener 660a that may extend from slit 660b of junction
box 660. In particular, the head of fastener 660a may be retained
within slit 660b, and the threaded portion of fastener 660a can
extend through slot 662b of Junction box L-foot 662. Junction box
60 may then be fastened to junction box L-foot 662 using nut 662c.
FIGS. 41B and 41C show perspective views of Junction box L-foot 662
and Junction box 660, respectively.
[0132] FIG. 42A shows a perspective view of wire management
assembly 770, in accordance with various embodiments. Wire
management assembly 770 can include L-foot 523, which may
correspond to L-foot 223, 323, or 423, for example, wire management
L-foot 762, which may be similar to junction box L-foot 662, and
wire clamp 772.
[0133] Wire clamp 772 may include a threaded bore that can receive
threaded fastener 762c inserted through slot 762b in wire
management L-foot 762. Threaded fastener 762 can thereby couple
wire clamp 772 to wire management L-foot 762. The threaded bore may
run through base member 772a of wire clamp 772, upon which wires
772c can be routed. Wires 772 can then be clamped into place by
virtue of clamping member 772b being coupled to base member 772a.
Clamping member 772b may include a number of channels for retaining
wires 772c against base member 772a. Coupling between clamping
member 772b and base member 772a may be effected using fastener
772d, which can extend through threaded bore 772e, visible in FIG.
42B. Wire clamp 772 may advantageously allow routing of wires 772d
in a wide range of directions with respect to L-foot 723 as
depicted in FIGS. 43A-43C.
[0134] FIG. 444 shows a flowchart of an exemplary process 400 for
assembling a solar panel installation, in accordance with some
embodiments.
[0135] It should be understood that the aspects, features and
advantages made apparent from the foregoing are efficiently
attained and, since certain changes may be made in the disclosed
inventive embodiments without departing from the spirit and scope
of the invention, it is intended that all matter contained herein
shall be interpreted as illustrative and not in a limiting
sense.
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